Module for protecting photovoltaic panel

ABSTRACT

The object of this invention is to protect a solar panel with attaching a protection module to four corners of a solar panel. Another object is for preventing the protection module from falling off when a solar panel is lifted up or tilted. Further object is that protection modules prevent collapse of cargo piles when solar panels are accumulated. The protection module comprises perpendicular sidewalls  41  and stage-like insertion member  44.  The sidewalls  41  cover two corner sides of the stacked solar panels. The insertion member  44  and the sidewalls  41  are molded integrally in such manner to connect two sides of the insertion member  44  to the inner surface  42  of the sidewalls  41.  The insertion member  44  is inserted between the stacked solar panels. A bank  45  is formed on the upper surface of the insertion member  44.  The bank  45  has hooking slopes  46  for holding the lower edge  34  of the frame of the solar panel by hooking on it. A terrace  47  is formed on the underside of the insertion member  44.  The terrace  47  has a ridge  48  for grasping the slope  33  of the upper edge  32  of the frame.

FIELD OF INVENTION

The present invention relates to a protection module for protecting asolar panel, especially the corner of a solar panel, inserted betweenthe adjacent stacked solar panels when manufactured solar panels arestacked for storage and transport.

BACKGROUND ART OF THE INVENTION

A photovoltaic module for converting sunlight into electricity ismanufactured as below. Photovoltaic layers made of silicon film andelectric conductive layers are formed on the back of a glass board.Further, a protection layer of synthetic resin is formed on thatsurface. The fringe of a photovoltaic module is surrounded with a framemade of processed drawn metal of aluminum or aluminum alloy to build asolar panel.

A frame is made of drawn metal with a connecting groove of square-Ucross section. The drawn metal with the square-U connecting groove ismounted on all edges around the photovoltaic module to build a frame(refer to FIG. 15).

The solar panel surrounded with frames as above is accumulated forstorage and transport. At this time, it is necessary to prevent collapseof cargo piles and breakage of solar panels. Therefore, the protectionmodules are attached to four corners of a solar panel when stacked. Itis already proposed in the following patent document 1.

PRIOR ART DOCUMENTS Patent Documents

[Patent document 1] JP2006-032978A

SUMMARY OF THE INVENTION Problem to be Solved by the Invention

The protection module as disclosed in the patent document 1 is forattaching to four corners of a solar panel. However, if they areattached to four corners of an accomplished solar panel, they fall offwhen the panel is lifted up. Therefore, the protection modules are notattached to solar panels until the solar panels are packaged.

A panel corner may be damaged at the period until packaging aftercompletion of a solar panel. Then, it is required to equip a solar panelwith a protection module immediately after completion of a solar panel.

The mass-produced solar panel is not a square but a rectangle. Two sortsof drawn metal are used for longer side and shorter side. Theircross-sections are different from each other. It is because ofmechanical strength of the frame for supporting the photovoltaic moduleand the convenience of installation of panels.

The drawn metal 2 on longer side, as shown in the section of FIG. 15(b), has an upper edge 22 to form a connection groove 21 with square-Ucross section for inserting the photovoltaic module and a lower edge 24.The drawn metal 3 on shorter side, as shown in the section of FIG. 15(c), has an upper edge 32 to form a connection groove 31 with square-Ucross section for inserting the photovoltaic module and a lower edge 34.

These drawn metal 2 on longer side and the drawn metal 3 on shorter sideare combined to build a frame 1 like a fine-art painting frame as shownin the plan view of FIG. 15( a).

Therefore, the protection module for a solar panel of this invention isinvented to achieve the following objects. The protection module doesnot fall off if a solar panel is lifted up or tilted when the protectionmodules are attached to each corner of frame 1 as constituted above. Andthe protection module prevents collapse of cargo piles at theaccumulation of solar panels.

Means to Solve the Problem

A protection module for a solar panel of this invention is forprotecting a solar panel as follows. The above-mentioned photovoltaicmodule is inserted to the frame to build a solar panel. The frame ismade of processed drawn metal with upper edge forming a connectiongroove with square-U cross section and lower edge. The protection modulehas rectangular sidewalls to cover two corner edges of the stacked solarpanel. The protection module has a stage-like insertion member. Theinsertion member is inserted between the stacked solar panels. Theinsertion member is molded integrally with connecting its two edges tothe sidewalls. A bank is formed on the top surface of the insertionmember. The bank has hooking slopes for hooking on lower edges of theframe. Terraces with ridge for grasping upper edges of the frame areformed on the underside of the insertion member.

Advantages of the Invention

The protection module of this invention has following advantages. Theprotection modules protect a solar panel when attached to the corners ofthe accomplished solar panel. The protection modules do not fall offwhen the solar panel is lifted up or tilted. The protection modulesprevent collapse of cargo piles at the accumulation of solar panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 It shows a plan view of the first embodiment of the protectionmodule of this invention.

FIG. 2 It shows a longitudinal section as cut at the line A-A in FIG. 1.

FIG. 3 It shows a bottom view of the first embodiment of the protectionmodule.

FIG. 4 It shows a figure to explain the state to attach the protectionmodule of the first embodiment of this invention to the corner of asolar panel.

FIG. 5 It shows a longitudinal section to indicate the accumulated stateof solar panels interposing the protection modules of the firstembodiment of this invention.

FIG. 6 It shows a plan view of the second embodiment of the protectionmodule of this invention.

FIG. 7 It shows a longitudinal section as cut at the line B-B in FIG. 6.

FIG. 8 It shows a bottom view of the second embodiment of the protectionmodule.

FIG. 9 It shows an upper perspective view (a) and a lower perspectiveview (b) of the protection module of the second embodiment.

FIG. 10 It shows a figure to explain the state of attaching theprotection module of the second embodiment of this invention to thecorner of a solar panel.

FIG. 11 It shows a plan view of the third embodiment of the protectionmodule of this invention.

FIG. 12 It shows a side view of the third embodiment.

FIG. 13 It shows a figure to indicate the cut-processed state of bothends of the drawn metal to build frames.

FIG. 14 It shows a bottom view (a) and a cross section (b) of the cornerof the frame, and a bottom view (c) of the main part of the corner ofthe frame to explain the usage state of the protection module of thethird embodiment.

FIG. 15 It shows a plan view (a) of the frame used for the solar panel,a longitudinal section (b) of the drawn metal on longer side of theframe and a longitudinal section (c) of the drawn metal on shorter sideof the frame.

MODES FOR CARRYING OUT THE INVENTION The First Embodiment

The first embodiment of the protection module for a solar panel of thisinvention is molded from synthetic resin as shown in the plan view ofFIG. 1, the cross section of FIG. 2 and the bottom view of FIG. 3. It isconstituted of two sidewalls 41, 41 and a stage-like insertion member44. Two sidewalls are perpendicular to the insertion member andintersect perpendicularly each other. Each edge of the insertion memberreaches to the inside 42 of the sidewalls.

A square flat bank 45 is formed at the corner apart from two sidewalls41, 41 on the upper surface of the stage-like insertion member 44. Thebank has two hooking slopes 46, 46 with wedge-shaped cross-section. Theslope is deeply cut to the inner side. These hooking slopes 46, 46 arefor hooking on the edge face of the wide lower edge 34 of the drawnmetal 3 as shown in the longitudinal section in FIG. 15( c).

On the lower surface of this insertion member 44, two terraces 47, 47are formed in parallel and adjacent to the inner surface 42 of thesidewalls 41, 41 except the corner area. The terrace 47 has a ridge 48for hooking on the slopes 23, 23 formed inside of the upper edges 22, 32of the drawn metals 2, 3 (refer to FIG. 15).

In addition, the cylindrical hollow 43 formed in the inside corner wherethe sidewalls 41 and 41 meet is formed so that the corner of the solarpanel might not be damaged when the corner of the solar panel wouldcollide against the inside corner of the sidewalls.

When the protection module as constituted as above is attached in thecorner of the solar panel, as shown in FIG. 4, the shorter side of thesolar panel is raised. The hooking slope 46 of the bank 45 of theprotection module 4 is hooked on the tip of the lower edge 34 of thesolar panel. As indicated by the arrow, the protection module 4 isturned upward.

The distance Y (refer to FIG. 2) between the hooking slopes 46, 46 andthe inner surface 42 of the sidewalls 41, 41 of the protection module 4is set up smaller than the width y (refer to FIG. 15) of the lower edge34 of the solar panel. Therefore, the corner 49 of the intersection ofthe sidewall 41 and the insertion member 44 fits to the corner 35 of thedrawn metal 3 of the solar panel. At this time, the flat surface of theinsertion member 44 carries out elastic deformation. As shown in FIG. 5,the protection module can be attached to the solar panel.

And, when the plural solar panels are stacked, as shown in thelongitudinal section in FIG. 5, the ridge 48 of the terrace 47 formed onthe underside of the insertion member 44 grasps the slopes 23, 33 formedinside of the upper edges 22, 32 of the drawn metals 2, 3 of the solarpanel stacked beneath. And also, the inner surface 42 of the sidewalls41, 41 under the insertion member 44 clutches the upper outer surface ofthe drawn metals 2, 3 just beneath of the stack. Therefore, collapse ofcargo piles would not be caused.

In addition, on the longer side and the shorter side of the frame 1, twosorts of drawn metals 2, 3 with different cross-section, especiallywidths x, y of the lower edges 24, 34, are used. Two hooking slopes 46,46 are formed at the symmetric position with respect to the diagonalline of the protection module 4. Therefore, the protection module isconstituted to be able to attach to any upper or lower corner of etherside of the frame 1.

The Second Embodiment

The second embodiment of the protection module for a solar panel is thatto reduce the used amount of the material while keeping mechanicalstrength.

As shown in the plan view of FIG. 6, in the cross section of FIG. 7, inthe bottom view of FIG. 8 and in the perspective view of FIGS. 9 (a) and(b), the protection module is constituted with two vertical sidewalls51, 51 crossing perpendicular to each other and the stage-like insertionmember 54. The sidewall is formed with flat tubular member that is madeof outer wall 511 and inner wall 513 supported by the partition wall512. Two edges of the insertion member contact the inner surfaces 52, 52of the sidewalls 51, 51.

On the upper surface of this stage-like insertion member 54, at thecorner apart from two sidewalls 51, 51, two banks 55, 55 are formed.Each bank is parallel to each sidewall crossing perpendicular to eachother. The overhangs 56, 56 are formed at the top of the side surfaceagainst the sidewalls 51, 51 of these two banks 55, 55. These overhangs56, 56 are, as shown in the longitudinal section in FIG. 15, connectedto the edge surface of the wide lower edge 34 of the drawn metal 3.

On the lower surface of this insertion member 54, plural terraces 57 areformed against the inner surfaces 52, 52 of the sidewalls 51, 51. Theterrace has a ridge 58 for grasping the slopes 23, 23 formed inside ofthe upper edges 22, 32 of the drawn metals 2, 3.

In addition, the hole 59 at the center of the stage-like insertionmember 44 is a hole opened at the part indifferent to the mechanicalstrength. It is opened to reduce the amount of the materials.

When the protection module constituted as above is attached to thecorner of a solar panel, same as the first embodiment, as shown in FIG.10, lifting up the shorter side of the solar panel, the overhang 56 ofthe bank 55 of the protection module 5 is hooked on the front end of thelower edge 34 of the solar panel, as indicated by the arrow, theprotection module 5 is turned up, the protection module 5 can beattached to the solar panel.

The Third Embodiment

In the second embodiment as explained above, the overhang 56 of the bank55 formed at the insertion member 54 is hooked on the lower edge 34 ofthe drawn material 3 on the shorter side of the frame 1. Then, theprotection module 5 is attached to four corners of the photovoltaicmodule 6.

About the attached protection module 5, one hand of the overhangs 56formed on two sides of the banks 55 is hooked on the lower edge 34 ofthe drawn metal 3 on the shorter side. But, it is not hooked on thelower edge 24 of the drawn metal 2 on longer side. Then, if it isattached with some offset in parallel to the drawn metal 3 on shorterside, a gap may arise between the inner surface of the protection module5 and the side surface of the drawn metal 2 on longer side.

Therefore, in the third embodiment, the protection module 5 isconstituted to attach to the corner of the frame 1 with positioning byhooking on both of the drawn metal 2 on longer side and the drawn metal3 on shorter side.

As shown in the plan view of FIG. 11 and the side view of FIG. 12, theprotection module 50 of the third embodiment has a cubical boss S formedon the diagonal line P-Q of the insertion member 54. The other structureis the same as the protection module 5 of the second embodiment.

Next, the position to form the cubical boss S is explained.

When both ends of the drawn metal 2 on longer side are processed bycutting, as shown in the plan view (a) and the bottom view (b) of FIG.13, in order to attach the tubular part 35 of the drawn metal 3 onshorter side, the step part 24 a is formed by cutting the front end ofthe lower edge 24.

When both ends of the drawn metal 3 on shorter side are processed bycutting, as shown in the plan view (c) and the bottom view (d) of FIG.13, in order to attach the tubular part 25 of the drawn metal 2 onlonger side, a notch part is formed by cutting the front end of thelower edge 34. At this time, it is cut at the line 36 deeper than thedotted broken line 37 reaching to the projection member 26 of the drawnmetal 2 on longer side. It is cut deeply to form the gap T with theprojection member 26 of the drawn metal 3 on shorter side.

Thus, in the state where the drawn metal 2 on longer side and the drawnmetal 3 on shorter side with both ends cut were connected at rightangle, the gap T is formed as shown in the bottom view (a) of FIG. 14.As shown in the cross section (b) of FIG. 14, this gap T is closed withthe lower edge 24 of the drawn metal 2 on longer side. But there is agap h between the lower surface of the lower edge 24 of the drawn metal2 on longer side and the upper surface of the lower edge 34 of the drawnmetal 3 on shorter side.

As shown in the bottom view (c) of FIG. 14 enlarged at the part of bossS, the boss S is square and its one side runs against the side ofprojection member 26. It is arranged so that the diagonal line P-Q goesthrough the center s of the boss S. And then, the height of this boss Sis set up lower than the gap h.

When the boss S is arranged thus, in a symmetrical position with respectto the diagonal line P-Q of the protection module 4, two banks 55 andthe boss S are formed. Therefore, it can be attached to anyone of fourcorners of the frame 1.

The boss S explained above is applicable also to the first embodiment.Moreover, a pillar is sufficient as the form of the boss S, withoutrestricting to a square pole. It is enough that the pillar is arrangedso that the diagonal line P-Q passes through the center of this pillar.

REFERENCE CODES

1 frame

2 drawn metal on longer side

3 drawn metal on shorter side

23, 33 upper edge

24, 34 lower edge

25, 35 tubular part

26 projection member

4, 5 protection module

41, 51 sidewall

42, 52 inner surface of sidewall

44, 54 insertion member

45, 55 bank

46 hooking slope

56 overhang

6 photovoltaic module

S boss

T gap

1. The protection module for protecting a solar panel made in such amanner to insert photovoltaic modules to the frame of processed drawnmetal with upper edge forming a connection groove of square-U crosssection and lower edge, comprising; rectangular sidewalls to cover twoedges at the corner of stacked solar panel, and a stage-like insertionmember molded integrally connecting two edges to the sidewalls for beinginserted between the stacked solar panels, wherein a bank with hookingslopes for hooking on the lower edge of the frame is formed on the topsurface of the insertion member, and terraces with ridges for graspingupper edges of the frame are formed on the underside of the insertionmember.
 2. A protection module for protecting a solar panel made in sucha manner to insert a photovoltaic module to a frame of processed drawnmetal with upper edge forming the connection groove of square-U crosssection and lower edge, comprising; rectangular sidewalls to cover twoedges at the corner of stacked solar panel, and a stage-like insertionmember molded integrally connecting two edges to the sidewalls for beinginserted between the stacked solar panels, wherein a bank with overhangsfor hooking on lower edges of the frame is formed on the top surface ofthe insertion member, and terraces with ridges for hooking on upperedges of the frame is formed on the underside of the insertion member.3. A protection module for protecting a solar panel made in such amanner to insert a photovoltaic module to a frame where is formed a gapbetween the downward projection member of the drawn metal on longer sideand the cut-processed lower edge of the drawn metal on shorter side,wherein the longer side drawn metal has upper edge forming a connectiongroove of square-U cross section, lower edge and projection member onthe bottom of lower edge, and the shorter side drawn metal has upperedge forming a connection groove of square-U cross section and loweredge, comprising; rectangular sidewalls to cover two edges at the cornerof stacked solar panel, and a stage-like insertion member moldedintegrally connecting two edges to the sidewalls for being insertedbetween the stacked solar panels, wherein a bank with overhangs forhooking on lower edge of the shorter side of the frame is formed at thesymmetrical position with respect to the diagonal line of the protectionmodule on the top surface of the insertion member and a boss to contactto the side surface of the projection member of the drawn metal onlonger side are formed, and the center of the boss is positioned on thediagonal line of the protection module.